transformable structure for a multi thread single line shuttle stitch line and method and machine for its realization

ABSTRACT

A multi-thread single-line shuttle stitch line, consisting of at least three threads, where each top thread is independently and separately connected with each bottom thread in a pre-determinable sequence of such connection through perforations in the material, with all of said top and bottom threads passing through said perforations, making one stitch line. The top threads can be intertwined, as can the bottom threads. A process for producing a multi-thread single-line shuttle stitch line, where at least three threads are involved to form said stitch line, with a stitch of said stitch line being formed by connecting a top thread with a bottom thread by cooperation of a needle and a shuttle, and a desired number of said needles with said top threads and a desired number of said shuttles with said bottom threads being used, with only one of said needles and one of said shuttles cooperating at a time, forming a current couple; with any of said needles forming said current couple with any of said shuttles in a desired sequence. Thus, a high degree of variability in the sequence of connecting the top and bottom threads allows for a flexible transformation of the structure of the stitch line in the process of its production. Needles are fixed to a revolver with needle bars located along the periphery of said revolver and oriented along the rotation axis of said revolver, and equipped with a device, which provides for the enabling of said current couple; shuttles are fixed to another revolver with said shuttles located along the periphery of said revolver, and are equipped with a device, which provides for the enabling said current couple.

CROSS REFERENCES TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT

1. Field of the Invention

The present invention relates to the manufacture of equipment for sewing technologies and methods for the sewing industry, the embroidered goods industry, the knitted goods industry, the leather industry and the shoe industry. The present invention comprises a technology for obtaining multi-thread single-line shuttle stitches.

2. Description of Prior Art and Existing Problems

At present only one type of machine for producing a single-line shuttle stitch line and only one type of shuttle stitch is known: a double-thread shuttle stitch making said stitch line (U.S. Pat. No. 2,862,468: ornamental stitch sewing machines).

The availability of just one type of shuttle stitch strongly hinders the potential for changes in the parameters of the stitch, which are limited to changing the step of the stitch and the thread tension. A shuttle stitch is rarely used in the sewing of knitted goods due to its low elasticity. At the same time, the shuttle stitch is sufficiently reliable and has a nice finished appearance.

In addition, the contemporary chain stitch used in sewing knitted goods has good elasticity but is not very reliable, and tends to deform the seam, causing corrugation, which creates the appearance of a defect in the finished product.

Hence, there is a demand for combining the benefits of these two kinds of stitches in a new type of stitch.

Another problem in sewing technology is the optimization of stitch line properties along the length of the line. The loads to which the stitch is exposed are different in different areas of a sewn article. In addition, the conditions of the stitch line operation are different, whereas the stitch line remains uniform along its length. For example, an article, such as a sleeve, is subject to various deformations in different areas: stretching at the elbow and corrugation at the bend. Also, the uniform stitch line often joins several layers of material, while the materials can be heterogeneous (woven fabric, knitted fabric, leather, etc.). Thus, the average properties of the uniform stitch line are intended to cover variable requirements, which ultimately limits the technological possibilities of creating new goods without the existing difficulties.

Further, the shuttle stitch structure assumes uneven deformation under stretching, where alternating stretched and squeezed areas are created (stretched areas occur around the perforation in the material, i.e. in the point of conjunction of the top and bottom threads, while the squeezed areas occur in the interval between two perforations). Such uneven deformation of the seam causes corrugation.

Thus, the main drawbacks of the contemporary single-line shuttle stitch line, which limit its application and degrade its operational properties and the appearance of the finished product, are as follows:

-   1. Low ability to stretch (i.e., limited elasticity); -   2. Limitations in controlling the stitch line/seam properties; -   3. Poor functional properties, which cannot be optimized along the     stitch line length, especially under conditions of complicated     design and variable operating conditions; and -   4. Seam corrugation in the operation process.

The aim of the present invention is a further improvement in the class of the shuttle stitch, due to the elimination of the drawbacks described above, by using the following principles:

-   1. Increased elasticity of the stitch line by replacing a rigid bond     in the interval between perforations with a flexible one; -   2. The elimination of corrugations due to overlapping stretching     zones; -   3. The introduction of duplicating bonds, thereby increasing the     reliability of the stitch line; -   4. Variability of the stitch structure, by varying the sequence of     conjunction of the top and bottom threads, which allows for a change     in the structure of the stitch along the length of the stitch line     for the optimization of the operational properties of the seam in     its different areas; and -   5. Improved reliability of the stitch line due to intertwined top     threads and/or intertwined bottom threads.

These and other objects and advantages of this invention are described in detail in the description of the invention contained herein.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises variations in the manufacturing of multi-thread single-line shuttle stitch lines, consisting of a system of top threads and a system of bottom threads, which threads are conjoined at the material perforation points. The top threads are joined with the bottom ones in a pre-determinable sequence, variable along the stitch line. This effect is obtained due to the following:

-   1. By utilizing a pre-determinable sequencing program for conjoining     the top and the bottom threads. The program is determined by the     desired structure of the stitch line. -   2. By the fact that each top thread is loaded into its own needle     and each bottom thread into its own shuttle. -   3. By operation through a means for sequentially engaging a required     needle and of another means for sequentially engaging a required     shuttle at one moment, providing conjunction of one of the top     threads with one of the bottom threads. A revolver can be used for     such means in both cases. Such revolver has needle bars located     along its periphery and oriented along its rotation axis, and the     other revolver has shuttles located along its periphery. Both     revolvers are equipped with devices, providing for enabling the     desired needle-shuttle couple, which will hereafter be called a     “current couple.” -   4. By a means for intertwining the top threads between each other     and a means for intertwining the bottom threads between each other     (as referenced below).     5. By operation of a means for providing a desired number of cycles,     where each cycle consists of the following steps:     -   (a) Bringing said current couple into the operating position for         said cycle;     -   (b) Passing of said top thread through material to be sewn by         said needle;     -   (c) Engaging said top thread by said shuttle;     -   (d) Throwing off said top thread onto said bottom thread;     -   (e) Extracting said needle out of said material and forming said         stitch by simultaneously tightening said top thread and said         bottom thread;     -   (f) Disabling of said current couple and enabling the subsequent         pre-determined current couple.

The proposed stitch line structure consists of a system of several top and several bottom threads joined through the perforations in the material. Such structure provides for mutual compensation of stretched and squeezed areas of the material and eliminates corrugation of the seam. Another benefit is the potential for changing or transforming the structure along the length of the stitch line in the process of the production of the stitch line. It permits the optimization of the properties of the seam in terms of its appearance, elasticity, wear resistance, etc.

The sequence of interaction of the top and the bottom threads is determined by the required structure of the stitches. The sequence of interaction can be controlled mechanically or digitally. These methods of control and programming are well known and widely used—e.g., in knitwear fabrics manufacturing (U.S. Pat. Nos. 4,467,737 and 4,359,953).

The loading of every upper thread into its needle and of every bottom thread into its shuttle can be provided by various methods used in conventional multi-thread sewing machines. (U.S. Pat. Nos. 3,433,191 and 4,993,335).

A means for sequentially engaging a required needle and a means for sequentially engaging a required shuttle at one moment, providing for conjunction of one of the top threads with one of the bottom threads, is not known from the prior art. These means could be provided by various ways. One of the ways is taught in the present invention. It comprises a needle unit (mechanism) and a shuttle unit (mechanism).

The needle unit is comprised of a revolver (needle revolver) with needle bars located along its periphery and oriented along its rotation axis. The shuttle unit also is comprised of a revolver (shuttle revolver), where the shuttles are similarly located along its periphery. Both revolvers are equipped with a device which provides for enabling the current couple. Both revolvers are provided with a means for turning and fixation. A Geneva wheel can be used for such purpose. (A Geneva wheel is a well-known mechanism in sewing machines; see, e.g., U.S. Pat. No. 4,702,183).

The utilization of both revolvers, due to the rotation of the needles and the shuttles around the rotation axes of the respective revolvers, can provide for the respective intertwining of the top threads with each other and of the bottom threads with each other.

DETAILED DESCRIPTION OF THE INVENTION AND DESCRIPTION OF THE DRAWINGS

The present invention can be easily understood from the detailed description of the preferred embodiment by reference to the attached drawings.

FIG. 1: This represents a general view of the structure of a multi-thread single-line shuttle stitch line (one of the possible embodiments) in the formation process; the structure is obtained due to the alternating connection of each top thread with each bottom thread through perforations (2) in the material (1) with intertwining (7) of the top threads (3 a and 3 b).

FIG. 2: For better understanding the main steps in the formation of a multi-thread single-line shuttle stitch line, both the top threads (3 a and 3 b) and both the bottom threads (4 a and 4 b) are symbolically placed on different levels. (A—passing of top thread through material (1) by a needle (5 a); B—engaging top thread (3 a) by shuttle (6 a); C—throwing off top thread (3 a) onto bottom thread (4 a); D—extracting needle (5 a) out of material (1) and forming the stitch by simultaneously tightening top thread (3 a) and bottom thread (4 a); E—preparation of another pre-determined current couple (needle 5 b and shuttle 6 b) for the next cycle.)

FIG. 3: Variants of the structure of single-line shuttle stitches:

-   -   a) Three thread shuttle stitch line made up of two top threads         (3 a and 3 b) and one bottom thread (4 a);     -   b) Five thread shuttle stitch line, where top threads (3 a and 3         b) are intertwined (7) and bottom threads (4 a, 4 b and 4 c) are         also intertwined (7).

FIG. 4: Sewing machine front view.

FIG. 5: Sewing machine axonometric view.

FIG. 6: Needle revolver.

FIG. 7: Needle revolver consisting of two needle modules (16 a and 16 b) and module mounting device (modular needle revolver) (22).

FIG. 8: Needle module.

FIGS. 1-8 disclose: 1—sewn material; 2—perforation; 3 a—first top thread; 3 b—second top thread; 4 a—first bottom thread; 4 b—second bottom thread; 4 c—third bottom thread; 5 a—first top thread needle; 5 b—second top thread needle; 6 a—first bottom thread shuttle; 6 b—second bottom thread shuttle; 6 c—third bottom thread shuttle; 7—thread intertwining; 8—needle unit (needle revolver); 9—shuttle unit (shuttle revolver); 10—mechanism of discrete rotation of the needle revolver (e.g. Geneva wheel); 11—mechanism for discrete rotation of the shuttle revolver (e.g. Geneva wheel); 12—needle bar (12 a—first needle bar; 12 b—second needle bar); 13—needle bar engaging mechanism; 14—needle bar catching device; 15—needle bar shoulder (15 a—first needle bar shoulder; 15 b—second needle bar shoulder); 16 a—module of needle and thread feeder mechanism of the first needle; 16 b—module of needle and thread feeder mechanism of the second needle; 17—bobbin holder with bobbin; 18—thread tension regulator; 19—thread take-up; 20—thread take-up eye; 21—thread take-up drive; 22—module mounting device; 23—shaft; 24—drum; 25—module housing; 26—needle unit housing; ω-angular speed of revolver rotation; t—small stitch step; T—big stitch step.

The principal steps of the multi-thread single-line shuttle stitch line formation cycle are as follows:

-   1. Needle (5 a) perforates the material (1) and the first top thread     (3 a) is passed through material (1) and reaches the extreme lower     point (FIG. 2, position A); -   2. The first top thread (3 a) is engaged by the first bottom thread     shuttle (6 a); then needle (5 a) goes up and forms a loop of the     first top thread (3 a), the shuttle (6 a) throws off the top thread     (3 a) onto the first bottom thread (4 a); here, needle (5 a) and     shuttle (6 a) make a current couple (marked with asterisks) (FIG. 2,     position B); -   3. Needle (5 a) is extracted from material (1) and thread (3 a) and     thread (4 a) are tightened simultaneously and a stitch is obtained     (FIG. 2, positions C and D); -   4. Material (1) is shifted for small stitch (t) (interval between     two nearest and adjacent perforations); the previous current couple     (needle 5 a and shuttle 6 a) is disabled; the following current     couple (needle 5 b and shuttle 6 b) is enabled; and the cycle is     repeated (FIG. 2, position E).

The cycles can be performed by the following mechanisms and devices. The mechanism for needle revolver discrete rotation (10) turns needle revolver (11), bringing desired needle (e.g., 5 a) into operating position; the simultaneous mechanism of shuttle revolver discrete rotation (12) brings desired shuttle (e.g., 6 a) into operating position; thus, the current couple of needle 5 a and shuttle 6 a is enabled. With this, the catching device (14) of mechanism (13) catches shoulder (15 a), thus enabling needle bar (12 a). The current couple then works in the manner of conventional sewing machines, i.e., as shown above in paragraphs 1, 2 and 3 of the principal steps of a multi-thread single-line shuttle stitch line formation cycle.

As described in paragraph 4 of the same, at the moment of the shift of the material for a small stitch (t), the mechanisms for the discrete rotation of needle revolver (10) and shuttle revolver (11) turn needle revolver (8) and shuttle revolver (9) respectively, bringing desired needle bar (any of the needle bars; e.g., (12 b)) and desired shuttle (any of the shuttles; e.g., (6 c)) into the operating position. (The remainder of the needle bars (12 a) and the shuttles (6 a and 6 b) are idle at this moment, as the current couple (5 b and 6 c) only operates at the given moment.) After this, a new stitch is formed.

The sewing machine can be designed with:

-   -   solid needle revolvers (FIG. 6);     -   interchangeable revolvers having different numbers of needles         and shuttles; and with     -   needle revolvers (modular needle revolvers) consisting of a         module mounting device (22) and the desired number of needle         modules (16) (see FIG. 7 and FIG. 8).

The solid needle revolver (FIG. 6) is comprised of a cylindrical drum (24), which is driven to make discrete rotations by rotation mechanism (10) via shaft (23). Each needle (5) is supplied with individual needle bars (12), bobbin holders (17), thread tension regulators (18), and thread take-ups (19). The motion of the thread take-up eye (20) is synchronized with needle bar (12) via thread take-up drive (21).

The modular needle revolver (FIG. 7 and FIG. 8) can be designed for various module mounting device capacities. Modules (16) are mounted on the module mounting device (22), which is connected with the mechanism of discrete rotation of needle revolver (10). All operations are similar to the ones described above for the solid needle revolver (FIG. 6).

The module (FIG. 8) is comprised of the casing (25) enclosing needle bar (12) connected via thread take-up drive (21) with thread take-up (19). The casing (25) has a bobbin holder with bobbin (17) and thread tension regulator (18). The thread take-up drive (21) may be designed, for example, as a kit of gears, transforming the motion on cogs on the needle bar (12) and thread take-up (19).

While this invention has been described in terms of a specific embodiment thereof, it is to be understood that it is not limited thereto, but rather only to the extent set forth hereafter in the claims, which follow. 

1. A multi-thread single-line shuttle stitch line, consisting of at least three threads, where each top thread is independently and separately connected with each bottom thread in a pre-determinable sequence through perforations in the material, with all of said top and bottom threads passing through said perforations to make one stitch line.
 2. A multi-thread single-line shuttle stitch line, as claimed in claim 1, where said top threads are intertwined.
 3. A multi-thread single-line shuttle stitch line, as claimed in claim 1, where said bottom threads are intertwined.
 4. A multi-thread single-line shuttle stitch line, as claimed in claim 1, where said top threads are intertwined and said bottom threads are intertwined.
 5. A process for production of a multi-thread single-line shuttle stitch line, where at least three threads are involved to form said stitch line, with a stitch of said stitch line being formed by connecting a top thread with a bottom thread by cooperation of a needle and a shuttle, and each top thread is loaded into its own needle and each bottom thread is loaded into its own shuttle; and the desired number of said needles with said top threads and the desired number of said shuttles with said bottom threads are used to form said stitch line, and only one of said needles and one of said shuttles cooperate at a time, forming a current couple; and any of said needles form said current couple with any of said shuttles in a desired sequence.
 6. A process for production of a multi-thread single-line shuttle stitch line, as claimed in claim 5, where the desired sequence is determined by the required structure of said stitch line, and said stitch line is formed by a desired number of cycles, where each cycle is the operation of said current couple, with each cycle consisting of the following steps: (a) bringing said current couple into operating position for said cycle; (b) passing of said top thread through material to be sewn by said needle; (c) engaging said top thread by said shuttle; (d) throwing off said top thread onto said bottom thread; (e) extracting said needle out of said material and forming said stitch by simultaneous tightening said top thread and said bottom thread; and (f) disabling said current couple and enabling a following predetermined current couple.
 7. A process for production of a multi-thread single-line shuttle stitch line, as claimed in claim 6, where the cooperation of said needles and shuttles is provided by a needle unit and a shuttle unit.
 8. A process for production of a multi-thread single-line shuttle stitch line, as claimed in claim 7, where said needle unit is comprised of a needle revolver with needle bars located along the periphery of said needle revolver and oriented along the rotation axis of said needle revolver, and equipped with a device, which provides for the enabling of said current couple; said shuttle unit is comprised of a shuttle revolver with said shuttles located along the periphery of the shuttle revolver and equipped with a device, which provides for enabling said current couple.
 9. A process for production of a multi-thread single-line shuttle stitch line, as claimed in claim 8, where said needle revolver is comprised of several needle modules.
 10. A process for production of a multi-thread single-line shuttle stitch line, as claimed in claim 9, where said needle module consists of a housing, enclosing a needle bar, with a thread bobbin and a thread feeder mechanism.
 11. A sewing machine for manufacturing a multi-thread single-line shuttle stitch line, wherein at least three threads are used; said sewing machine basically comprising a means for cooperation of a needle and a shuttle, a desired number of needles with top threads, a desired number of shuttles with bottom threads, a feed mechanism to feed material to be sewn, a drive means to drive said means for cooperation of a needle and a shuttle, and the feed mechanism, and further including a means for synchronization thereof; said sewing machine providing for the conjoining of said threads at the material perforation points in a pre-determinable sequence, which sequence is variable along the stitch line, and which sequence is obtained by utilizing a pre-determinable sequencing program for conjoining the threads, with only one of said needles and one of said shuttles cooperating at a time, forming a current couple; and any of said needles forming said current couple with any of said shuttles in a desired sequence.
 12. A sewing machine for manufacturing a multi-thread single-line shuttle stitch line, as claimed in claim 11, where said means for cooperation of said needles and shuttles are a needle unit and a shuttle unit.
 13. A sewing machine for manufacturing a multi-thread single-line shuttle stitch line, as claimed in claim 12, where said needle unit is comprised of a needle revolver with needle bars located along the periphery of said needle revolver and oriented along the rotation axis of said needle revolver, and equipped with a device, which provides for the enabling of said current couple; said shuttle unit is comprised of a shuttle revolver with said shuttles located along the periphery of the shuttle revolver and equipped with a device, which provides for enabling said current couple.
 14. A sewing machine for manufacturing a multi-thread single-line shuttle stitch line, as claimed in claim 13, where said needle revolver is comprised of needle modules.
 15. A sewing machine for manufacturing a multi-thread single-line shuttle stitch line, as claimed in claim 14, where said needle module is comprised of a housing, enclosing a needle bar, with a thread bobbin and a thread feeder mechanism. 